Indirect bonding trays for orthodontic treatment and methods for making the same

Abstract

An indirect bonding tray places orthodontic appliances in precise, predetermined positions on the teeth of a patient. The indirect bonding tray includes a first matrix material that extends over a set of appliances and a second matrix material that extends over the first matrix material. The indirect bonding tray also includes at least one occlusal stop member that is connected to the second matrix material for firm, relatively hard contact with the occlusal tips of the patient's teeth when the tray is received in place over the patient's dental arch.

1. An indirect bonding tray for orthodontic treatment comprising:
 a set of orthodontic appliances for a dental arch; 
 a first matrix material extending over the appliances; 
 a second matrix material extending over the first matrix material, wherein the second matrix material includes a portion having a surface with a configuration that matches the configuration of a portion of side tooth surfaces of the dental arch, and wherein the second matrix material exhibits a tensile stress at 20 percent elongation that exceeds the tensile stress at 20 percent elongation of the first matrix material; and 
 an occlusal stop member connected to the second matrix material, the occlusal stop member including at least one section having a surface with a configuration that matches at least a portion of an occlusal tooth surface of the dental arch for contact with the dental arch, wherein the occlusal stop member has a Shore A hardness greater than the Shore A hardness of either the first or second matrix material. 
 
     
     
       2. An indirect bonding tray for orthodontic treatment according to  claim 1  wherein the first matrix material includes a portion having a surface with a configuration that matches the configuration of a portion of side tooth surfaces. 
     
     
       3. An indirect bonding tray for orthodontic treatment according to  claim 1  wherein the first matrix material surrounds each appliance. 
     
     
       4. An indirect bonding tray for orthodontic treatment according to  claim 1  wherein the appliances have occlusal, facial and gingival sides, and wherein the first matrix material is in contact with the occlusal, facial and gingival sides of the appliances. 
     
     
       5. An indirect bonding tray for orthodontic treatment according to  claim 1  wherein the second matrix material surrounds at least a portion of the occlusal stop member. 
     
     
       6. An indirect bonding tray for orthodontic treatment according to  claim 1  wherein the second matrix material is connected to the occlusal stop member by a mechanical interlock. 
     
     
       7. An indirect bonding tray for orthodontic treatment according to  claim 1  wherein the tray includes an external facial surface and wherein the second matrix material presents at least part of the external facial surface. 
     
     
       8. An indirect bonding tray for orthodontic treatment according to  claim 1  wherein the tray includes an external lingual surface and wherein the second matrix material presents at least part of the external lingual surface. 
     
     
       9. An indirect bonding tray for orthodontic treatment according to  claim 1  wherein the stop member comprises rapid prototyping material. 
     
     
       10. An indirect bonding tray for orthodontic treatment according to  claim 1  wherein the first matrix material exhibits tensile stress in the range of about 62,000 Pascal to about 248,000 Pascal at 20 percent elongation. 
     
     
       11. An indirect bonding tray for orthodontic treatment according to  claim 1  wherein the second matrix material exhibits tensile stress in the range of about 0.8×10 6  Pascal to about 3.3×10 6  Pascal at 20 percent elongation. 
     
     
       12. An indirect bonding tray for orthodontic treatment according to  claim 1  wherein the first matrix material exhibits tensile stress in the range of about 112,000 Pascal to about 136,000 Pascal at 20 percent elongation. 
     
     
       13. An indirect bonding tray for orthodontic treatment according to  claim 1  wherein the second matrix material exhibits tensile stress in the range of about 1.1×10 6  Pascal to about 1.4×10 6  Pascal at 20 percent elongation. 
     
     
       14. An indirect bonding tray for orthodontic treatment according to  claim 1  wherein the second matrix material exhibits a tensile stress at 20 percent elongation that exceeds the tensile stress at 20 percent elongation of the first matrix material by a ratio in the range of about 5:1 to about 20:1. 
     
     
       15. An indirect bonding tray for orthodontic treatment according to  claim 1  wherein the occlusal stop member includes a handle that extends in a facial direction past the second matrix material. 
     
     
       16. An indirect bonding tray for orthodontic treatment according to  claim 1  wherein the occlusal stop member includes two posterior sections having at least one recess with a configuration that matches an occlusal tip of a molar tooth and at least one anterior section with at least one recess having a configuration that matches the configuration of an occlusal tip of an anterior tooth. 
     
     
       17. An indirect bonding tray for orthodontic treatment according to  claim 16  wherein the occlusal stop member also includes a connecting section interconnecting each anterior section and each posterior sections, wherein the connecting section is more flexible than each anterior section and each posterior section. 
     
     
       18. An indirect bonding tray for orthodontic treatment according to  claim 17  wherein the connecting section does not include a recess having a configuration that matches the configuration of an occlusal tip of a tooth. 
     
     
       19. An indirect bonding tray for orthodontic treatment according to  claim 1  wherein the occlusal stop member is the only stop member of the tray that has a hardness that is greater than the hardness of the second matrix material.